By Heidi J. Ellsworth. 

Advancing retrofit solutions through engineering, collaboration and industry partnership. 

In today’s evolving construction landscape, the role of building enclosure professionals has never been more critical. From ensuring long-term performance to meeting increasingly complex energy and structural requirements, consultants are at the forefront of delivering smarter, more resilient buildings. That is why partnerships between manufacturers and organizations like the International Institute of Building Enclosure Consultants (IIBEC) are so important to the future of the industry. 

For companies like Roof Hugger, this commitment goes beyond participation. It is about actively supporting the consultants, engineers and professionals who are specifying and guiding building enclosure solutions every day. They have built a reputation of delivering proven, engineered retrofit systems designed specifically for metal buildings. These solutions are not just about covering an existing roof. They are about enhancing the entire building system. By eliminating the need for a costly tear-off, their retrofit approach helps extend the life of existing structures while improving structural integrity, increasing energy efficiency and delivering long-term value. 

This aligns directly with the priorities of IIBEC members who are tasked with evaluating total building performance. Consultants are increasingly looking for solutions that address multiple challenges at once, including sustainability, cost control and durability. Roof Hugger’s engineered systems provide a practical path forward, offering tested and reliable options that meet these demands while minimizing disruption to building occupants. 

What stands out is Roof Hugger’s willingness to support projects at every stage. Whether a consultant is in the early phases of evaluating options or preparing specifications for a complex retrofit, their team offers expertise that ranges from individual Hugger components to complete engineered systems. This collaborative approach reflects a deep understanding of how building enclosure consultants work and what they need to deliver successful outcomes. 

Equally important is the company’s focus on tailoring solutions to each project. No two buildings are exactly alike, and retrofit systems must account for varying structural conditions, climates and performance goals. By providing preliminary evaluations and customized engineering support, Roof Hugger helps ensure that each system is designed with precision and purpose. 

Their message to the industry is straightforward and resonates strongly with the IIBEC community. At Roof Hugger, they are committed to providing proven, engineered retrofit solutions that extend the life of metal buildings while improving performance and efficiency without the need for tear-off. They welcome the opportunity to support projects at any stage, offering guidance, technical insight and responsive service to meet the specific needs of each client. 

As the demand for retrofit solutions continues to grow, partnerships between manufacturers and organizations like IIBEC will play an increasingly important role. By aligning innovation with education and professional standards, companies like Roof Hugger are helping to shape a more sustainable and resilient future for the built environment. 

For more information, visit the Roof Hugger directory on RoofersCoffeeShop® and MetalCoffeeShop®.

By Jesse Sanchez. 

Learn how a metal-over-metal retrofit improved durability, appearance and wind resistance for a complex campus building. 

When a roof reaches the end of its service life, building owners must weigh performance, cost and operational impact. For universities and other occupied facilities, that challenge becomes more complex, as construction cannot disrupt daily use. A retrofit at the University of Hawaii’s Biomedical Sciences building, supported by Roof Hugger, illustrates how metal-over-metal systems can address those competing priorities while delivering long-term value. 

Completed as part of a $1.1 million remodel, the project included the installation of approximately 18,000 square feet of standing seam metal roofing over the existing system. The upgrade was driven by both functional and aesthetic concerns, as the original roof had reached the end of its service life, showing signs of chalking, fading and overall wear. 

Rather disrupting ongoing school activities with a full tear-off, the retrofit utilized a sub-purlin system to support the new metal roof. This approach allowed crews to install the new roof directly over the existing structure, minimizing interference with building operations while improving overall system performance. The project brought together multiple contributors, including Roof Hugger retrofit framing systems, Custom Metal Roofing, a division of HPM Building Supply, Beachside Roofing as the installer, Designer Built Systems as general contractor and architect Richard Matsunaga. 

The building’s design introduced additional complexity. Its hipped geometry transitions from a 3:12 slope to a steep 12:12 pitch before extending into a vertical central tower. Managing these changes required precise engineering to ensure consistent structural integrity and weather performance across the entire roof system. 

Wind resistance also played a critical role in the project’s design. Although local requirements at the time called for 80 mile-per-hour wind speeds, the system was installed to meet pressures associated with 100 mile-per-hour conditions, aligning the building with anticipated code updates and strengthening long-term resilience. 

Ultimately, the project demonstrates how modern retrofit solutions can extend service life, enhance performance and adapt existing structures to evolving standards, all without interrupting the environments they are designed to protect. 

Learn more about how metal-over-metal retrofit systems improve durability, meet evolving wind standards and minimize disruption for occupied buildings!

By Jesse Sanchez. 

Understanding framing, load paths and real-world testing helps ensure your project is a code-compliant and durable metal-over-metal retrofit. 

When an existing metal roof reaches the end of its service life, retrofitting is often the easiest, least invasive and most cost-effective replacement strategy. Companies such as Roof Hugger emphasize that beneath every successful metal-over-metal project is a structural story that cannot be overlooked. Understanding the roles of purlins and subpurlins is essential to delivering a high-quality, code-compliant and long-lasting new roof. 

In older pre-engineered buildings, purlins are typically spaced five feet on center, eight inches deep and formed as Z-shaped members spanning from frame to frame. Many are continuous-span members that overlap at frames and act together to distribute loads. Their bracing needs depend heavily on the roof system above them. Through-fastened panels can provide diaphragm strength, often reducing additional bracing, while standing-seam systems offer minimal diaphragm support and require more structural reinforcement.  

During a retrofit, two structural issues must be addressed: performance and weight. Panel clip spacing must be analyzed for code-compliant attachment, and panel behavior can vary significantly when fastened to subpurlins instead of full-depth purlins. Additional loads, including photovoltaics or rooftop equipment, must also be evaluated against existing capacity.  

Notched subpurlins are often the most cost-effective framing option because they minimize added height and dead load. However, subpurlins are not the same as purlins. Differences in steel grade, flange size and geometry directly affect uplift and pullout performance. Some suppliers use lower yield Grade 30 steel, which can reduce pullout values by as much as 50%.  

Because panel combinations, gauges and framing variables vary widely, computer simulations alone are not enough. Testing under standards such as ASTM E1592 and AISI S908 provides the validated data needed to make informed decisions. In metal retrofit design, real performance testing, not theoretical modeling, ultimately protects both the structure and the owner’s investment. 

Learn more about why purlins and subpurlins matter in metal retrofit design and how proper analysis, material selection and validated testing protect structural performance and long-term investment!

Honoring Mark's life and accomplishments.

We are deeply saddened to share that my longtime pillar of the metal building community Mark James passed away on Sunday, March 22, 2026. Mark is survived by his wife of 55 years Paula, his son Jarrod, his grandchildren Brooklyn, Harley, Julian and his great-grandson Trevon. A service will be held in Dallas in the near future.

Mark’s career began remarkably early. At just eight years old, he worked as a blueprint boy for his father’s company. He later attended the University of Missouri and continued his education at night through the Finlay School of Engineering in Kansas City, Missouri.

In the late 1970s, Mark designed roof systems using dimensional lumber to retrofit flat roofs with truss-framed sloped roofs — Ultimately contributing to more than 30 million square feet of retrofit projects. In 1981, he was recruited by Kirby Building Systems as their Special Projects Manager, prompting a move to Houston, Texas. In 1984, he accepted a district manager position with United Structures of America, and four years later, in 1988, he became a partner in Genesis Group, Inc. of Baton Rouge, where he worked on both new metal buildings and retrofit projects.

Moving now to Dallas, Texas, Mark joined Roof Hugger, Inc. in 2009, where his impact was immediate and lasting. He developed standard details, product specifications, sales presentations and represented the company at numerous industry association meetings. He became deeply involved in the Metal Construction Association (MCA), eventually serving as chairman of the retrofit council. In that role, he helped create many of the AIA education programs that continue
to be used today.

He was a familiar face at RCI (now IIBEC), MBCEA and other industry organizations. Mark also played a major role in creating and setting up many of the METALCON Live Demo displays, including the Metal Roofing Games Competition and the Solar Bay exhibit. To say he was well known in our industry is an understatement.

After retiring from Roof Hugger in 2014, Mark founded his consulting firm, RetroSpec, LLC, continuing to advise Roof Hugger, MCA and many other metal-related companies. He and Paula then moved to Hot Springs, Arizona, where they enjoyed a beautiful home and surroundings and after buying a large camper, they traveled across the country while he continued consulting remotely.

In 2019, Mark received MCA’s prestigious Larry A. Swaney Award, recognizing his commitment to communication, cooperation, unity and the advancement of the metal construction industry. Beyond his professional achievements, Mark was an accomplished artist, cabinet maker and interior designer. He loved his family deeply, and those of us who knew and worked with him will miss him profoundly.

By Jesse Sanchez. 

How retrofit testing is redefining metal roof performance and why documented, real-world structural testing is essential. 

Metal building owners are asking a more direct question than they did a decade ago. The issue is no longer simply whether a roof can be replaced, but whether the existing structure can handle added weight, comply with current codes and support future rooftop systems such as solar. That concern is pushing the industry to focus on structural retrofits that are tested, measured and documented. On this episode of MetalCast™, Dale Nelson and D.J. Highnote of Roof Hugger explained how testing changed the way retrofit performance is evaluated. They emphasized that if a system claims to strengthen a building, it must prove it. 

Dale said the company’s approach began with a hard lesson in the field. “It was structurally not correct, but that's all we knew to do at the time,” he said, describing early overlay methods. That realization led to the creation of a notched Z component designed to create a direct structural connection into the building frame. Still, observation was not enough. Crews noticed stiffer roofs after installation. “After you put the roof hugger on, it didn't spring anymore,” Dale said. But building owners and engineers needed more than feel. They needed data. 

To provide it, the company constructed a 50-foot multi-span test bed to simulate real building conditions. “We did over 30 tests of various gauges, profiles, heights of parts,” Dale said. D.J. emphasized why that mattered. “If you can imagine taking on this project of building a 50-foot long test bed, which is going to be a multi-span Perlin, which is what a metal building is really going to be,” he said. The goal was to mirror actual building behavior, not idealized lab conditions. 

The result is documented capacity increases supported by sealed engineering calculations that engineers can review and verify. As D.J. put it, “Not every test goes the way you think it's going to,” a reminder that real performance is uncovered through repeated testing, not assumptions. In today’s market, structural strengthening cannot rely on reputation or field impressions alone. It must be tested, calculated and clearly proven. 

Listen to the podcast or Watch the interview to learn more about how retrofit testing is redefining metal roof performance and why documented, real-world structural testing is essential. 

By Emma Peterson. 

Join The Coffee Shops™ crew and our industry partners in Sacramento for four days of education, innovation and industry connection. 

The Coffee Shops™ crew is putting the finishing touches on our travel plans to get to Sacramento, California March 12–15, 2026 for the International Institute of Building Enclosure Consultants (IIBEC)’s International Convention and we want to see you at our booth and soundstage, sponsored by Western Colloid!  

This year’s show is predicted to host “1,700 consultants, architects, engineers, design professionals and other experts” for four days of learning, networking and more! With national sponsors like Carlisle, Elevate™, GAF, IB Roof Systems™, Johns Manville, Polyglass USA Inc., Sika Corporation, SOPREMA and Versico, this show is a must-attend for professionals in all parts of the roofing world.  

Expert-led education  

This show gives attendees a chance to learn from a variety of industry leaders and experts through their cutting-edge education sessions. Here are some of the incredible presenters that will be at this year’s show:  

• Trent Cotney of Adams and Reese will be hosting a “State of the Industry” session that will explore contract provisions and other emerging regulatory trends.  
• Darren Perry of SOPREMA has a session that discusses how low slope roofing can be enhanced in response to severe climate risks. 
• Amrize’s National Technical Manager Victor Rosenthal and Project Manager Rachael DeMeio will be teaching about trends in roof re-cover applications this year. 
• Jennifer Stephan from Benchmark’s session will dive into the world of Refrigerated Processing and Cold Storage Operations in relation to industrial roofing projects.  

Check out the full speaker list online!

An expo floor route 

The Coffee Shops crew will be on the expo floor hosting a soundstage at booth #1113! Here’s just a few of the other Coffee Shops friends and partners that can be found on IIBEC’s 2026 International Convention expo floor:  

• All Weather Insulated Panels (booth #1216) 
• Anchor Products (booth #907)  
• ATAS International (booth #728)  
• BITEC Inc. (booth #1023) 
• Brava Tile (booth #208) 
• CertainTeed (booth #227)  
• General Coatings Manufacturing (booth #926) 
• H.B. Fuller (booth #113) 
• ICP Building Solutions Group (booth #133) 
• IKO Industries (booth #426) 
• Leister (booth #619) 
• Malarkey Roofing Products (booth #213) 
• MuleHide (booth #814) 
• Roof Hugger (booth #707) 
• S-5! (booth #1019) 
• Sheffield Metals International (booth #625) 
• Sherwin Williams Roofing Solutions (booth #422) 
• Tremco (booth #321) 
• USG Securock (booth #401) 
• Western Colloid (booth #923) 
• Westlake Royal Roofing Solutions (booth #433) 

Explore the full expo floor map!

Register today and make sure you stop by to say hi to us and our industry friends at the IIBEC’s 2026 International Convention!

By Jesse Sanchez. 

A company built on a dedication to quality and craftsmanship finds new ways to make old metal buildings feel safe again. 

As shared on this episode of Roofing Road Trips®, Dale Nelson, founder and president of Roof Hugger, joined vice president D.J. Highnote to discuss how a structural problem led to a new approach to metal retrofit. When Dale first began retrofitting metal buildings, the standard approach was straightforward: lay hat channel across the high ribs of the existing roof and fasten it down. It was common practice. But Dale said it was not structurally sound. “The usual approach wasn’t structurally correct,” he said. “We needed something that connected straight down into the structure below.” 

That realization led to the development of the notched Z, a structural member designed to sit over the existing metal panel and fasten directly into the purlin below. Instead of relying on the old panel for support, the system created a direct load path into the building’s framing. As a result, the roof assembly behaved differently under weight and movement. 

“After you put the Roof Hugger on, it didn’t spring anymore,” Dale said. The reduced deflection confirmed that the connection was doing more than holding panels in place. It was changing how the structure responded under load. That observation prompted further testing. 

To measure the impact, Roof Hugger constructed a 50-foot-long, two-bay test bed to evaluate how retrofit components performed under controlled conditions. The company conducted more than 30 tests across different gauges, profiles and part heights. And engineers analyzed how each variation affected strength and deflection. 

The data was then incorporated into proprietary engineering software. Rather than evaluating only purlin capacity, the modeling accounts for the entire assembly, including laps, fasteners and connections; the components that often determine where a system will fail first. 

That emphasis on understanding the full structural system continues to shape how Roof Hugger approaches retrofit projects today. 

D.J. said structural clarity remains central to metal-over-metal retrofit, especially when contractors compare it to other recover options. “When they install TPO on a metal building, they’re considering that roof panel a deck and it’s not,” D.J. said. “It’s not a structural deck.” Metal buildings are engineered for channeled water flow along panel ribs. Water is designed to move quickly off the roof while purlins and panels deflect within controlled limits. When a flat membrane system changes that profile, drainage patterns and load distribution can shift, particularly under snow or ponding conditions. 

D.J. also noted that modern metal finishes often outlast rooftop solar systems. “That metal roof is going to last twice as long as the photovoltaic panels,” he said. “And they mount externally without penetrating the roof panel.” For building owners, a structurally connected metal-over-metal system provides strength, preserves drainage performance and creates a long-term platform for future upgrades. 

Listen to the podcast or Watch the interview to learn more about Roof Hugger and how retrofit testing shapes stronger metal roofs for long-term performance! 

By Jesse Sanchez. 

What Roof Hugger’s leaders say about the importance of purlin strength for aging metal buildings. 

Metal roofs are everywhere and as they age, owners must decide whether to patch, replace or upgrade their roof with long-term performance in mind. In this episode of MetalCast™, Roof Hugger leaders Dale Nelson and D.J. Highnote kept returning to one point: retrofit success depends on what happens at the purlin. If the structure underneath cannot safely carry added weight or meet modern load expectations, the roof above it likely won’t last as long as its expected roof life. 

D.J. framed the challenge in practical terms. “When we do a retrofit or an overlay, we’re adding weight. We already know a lot of these existing buildings don’t meet the new local loads,” he said. In many pre-engineered metal buildings, purlins were originally designed with tight tolerances and little excess capacity and as codes evolve and rooftop equipment or additional dead load is added, stress on those members increases. If the purlins cannot safely carry that weight, deflection rises and long-term performance declines. That is where Roof Hugger’s notched Z system comes in, creating a direct structural connection to the existing purlin or supporting member so the load path is reinforced rather than resting on aging roof panels. The retrofit framing works with the existing structure to help redistribute loads and increase capacity where it is needed most. Rather than assuming improvement, the company quantified it, emphasizing that credibility in the metal building world is earned through defensible data, not anecdotes and providing engineers and contractors with calculations that support informed decisions instead of guesswork. 

To document what was happening in the field, Dale said the company built a purpose-made test bed and ran over 30 tests across different gauges, profiles and part heights. The goal was not only to see whether purlins got stronger, but to understand where failures could occur across the assembly. “We have probably learned more from our test failures than we ever did out of our successes,” Dale said, explaining that each failure revealed where adjustments in geometry, gauge or connection design could improve performance. Those results were later used to refine part profiles and support modeling and engineered calculations, giving contractors clearer guidance on how much additional capacity a system could provide and where reinforcement was still required. 

For contractors and building owners, the challenge is that aging metal buildings were often engineered with little excess capacity and modern demands such as higher wind ratings, updated snow loads, rooftop equipment and solar, which push those limits further. Roof Hugger’s solution is not simply to cover what exists, but to reinforce it. Through controlled testing, measured load increases and engineered calculations, the company has developed a retrofit framing system that strengthens the purlins and restores confidence in the structure beneath the roof. That data-backed approach gives contractors something more than a product, it gives them documentation they can present to engineers, inspectors and owners. 

For building owners weighing retrofit options, purlin strengthening is not an add-on, it is the structural foundation that determines what a building can handle next, from code-driven loads to future rooftop upgrades. 

Listen to the podcast or Watch the interview to learn more about how purlin strengthening and real-world testing can transform aging metal buildings!

By Jesse Sanchez. 

A contractor-led idea grew into a widely trusted retrofit approach by responding to real-world challenges and validating performance through decades of testing. 

In this episode of Roofing Road Trips®, Karen Edwards sat down with Dale Nelson, founder of Roof Hugger, to trace how a practical field challenge evolved into a nationally recognized retrofit solution. Roof Hugger did not emerge from a boardroom strategy session or a market study. It took shape on an aging metal roof where conventional retrofit methods failed to meet structural realities, an experience that set the tone for the company’s direction after it was officially incorporated in 1991 and continues to influence how it approaches retrofit design today. 

Dale traced the origin of the system to his long professional relationship with Red McConaughey and a single reroofing project on an 8,000-square-foot building. At the time, the industry standard relied on rigid hat channels installed across existing roof ribs. While common, the method did little to accommodate metal’s natural expansion and contraction. When Dale questioned the approach, engineering guidance confirmed his concerns and made clear the solution would not perform long term. 

Rather than accept that limitation, Dale and Red looked for an alternative. The answer came in the form of a notched Z-shaped purlin that could connect structure to structure while still allowing the roof system to flex. Early fabrication costs were steep, but by working with fabricators on volume pricing, the pair produced workable prototypes. Those early retrofits performed as intended and the concept gained momentum through repeat projects. Dale shared, “We formed a corporation and off we went. We had rocking sales our first year of $9,600.” 

Building credibility became the next priority. After securing a patent in 1994, the company focused on education and visibility, leaning on industry publications and mentors to help communicate value in a market still defining retrofit standards. That outreach positioned the system as a practical alternative rather than a theoretical one. 

As Roof Hugger grew, its emphasis expanded beyond product development to industry engagement. Dale has pointed to association involvement as a turning point, providing insight into installer needs, manufacturer expectations and upcoming code changes. That perspective informed material choices, standardized specifications and a long-term commitment to testing. 

Testing soon became a defining pillar. With few formal protocols available in the early 1990s, Roof Hugger worked with engineers to develop its own methods before transitioning to established standards such as ASTM E1592. Continued research, including wind tunnel and purlin strength testing, revealed added structural capacity benefits that reshaped how retrofit projects could be evaluated. Dale stated, “You know, Red’s little idea really blossomed into something none of us could have imagined back in the early 90s.” 

Listen to the podcast or Watch the interview to learn more about Roof Hugger and its metal roof retrofit solutions!

By Jesse Sanchez. 

With millions of aging metal-roofed structures nationwide, strategic retrofits are reshaping value, resilience and long-term performance. 

For many owners who built metal facilities in the 1970s and 1980s, the priority at that time was affordability. These buildings were designed to provide what was often described as “shade and shelter,” allowing businesses to operate at the lowest possible cost. According to Roof Hugger, LLC President Dale Nelson, maintenance was rarely the focus as owners concentrated on staying afloat and navigating economic cycles. Today, those same buildings are often paid off, but they are increasingly out of step with modern codes, efficiency standards and operational expectations. 

That disconnect has created a new opportunity. Updated zoning requirements, stricter building codes and rising impact fees have significantly increased the cost of new construction. As Dale put it, “They don’t build them like that anymore.” With more than 1.6 billion square meters of metal-roofed buildings now between 20 and 50 years old, reinvestment has become an attractive alternative to starting from scratch. 

The most effective place to begin is the roof. Many early metal buildings relied on screw-down roof systems that paired 30-year panels with fasteners that often failed much sooner. These roofs are easily recognized by rows of exposed fasteners across the surface. Retrofitting the roof establishes a stable foundation for broader improvements, allowing owners to transition to standing seam systems and secure longer-term finish and weather-tight warranties. 

Roof retrofits also open the door to structural and financial benefits. Strengthening existing purlins can bring buildings into compliance with current codes, potentially lowering insurance costs while preparing the roof for future equipment such as solar. Dale also highlights the role of IRS Section 179 deductions and available energy credits in improving the return on investment. 

With the roof addressed, attention turns to wall openings. Older windows, overhead doors and personnel doors often fail to meet today’s performance standards. Modern replacements are engineered with reinforced components designed to reduce the risk of major structural damage. 

Finally, exterior upgrades can protect vulnerable lower wall areas and refresh curb appeal. Wainscot systems, entry enhancements and updated finishes help older buildings better reflect current branding or prepare them for resale. Together, these improvements can significantly extend a building’s useful life and reposition it as a durable, code-compliant asset. 

Learn more about how strategic retrofits can unlock the full potential of older metal buildings!